ABB CI853K01 | Dual RS232-C Communication Interface Module – Specifications & Industrial Integration Guide

Description

System Architecture & Operational Principle

• ABB AC 800M Controllers: Receives control commands and sends status updates via the CEX bus.
• External Serial Devices: Links to third-party PLCs, HMI panels, sensors, or legacy systems using RS232-C cables (or fiber converters for long distances).

Upstream Communication

Downstream Communication

Operational Advantages

• Protocol Versatility: Supports ABB’s proprietary COMLI protocol (for controller-to-controller communication) and open Modbus RTU (for third-party device integration), eliminating the need for additional gateways.
• Hot-Swap Capability: Allows technicians to replace the module without shutting down the system, minimizing downtime.
• Electrical Isolation: RS422/RS485 ports feature 500V galvanic isolation, preventing ground loops and protecting sensitive electronics from voltage spikes.

Core Technical Specifications

Attribute​	Specification​
Product Type​	Dual RS232-C Communication Interface Module
Part Number​	CI853K01 (Alias: 3BSE018103R1)
Communication Ports​	2×RS232-C (DB9 female); 1×RS422/RS485 (screw terminal/DB9)
Supported Protocols​	COMLI (Master/Slave), Modbus RTU (Master), ASCII (custom)
Baud Rate Range​	75–19,200 bps (configurable)
Power Supply​	24V DC (from AC 800M backplane); 100 mA typical consumption
Operating Temperature​	-25°C to +70°C (-13°F to 158°F)
Storage Temperature​	-40°C to +85°C (-40°F to 185°F)
Humidity​	5–95% non-condensing
Protection Class​	IP20 (dust-proof; must be installed in a cabinet)
Dimensions (W×H×D)​	~59 mm × 185 mm × 127.5 mm (2.3 in × 7.3 in × 5.0 in) (including baseplate)
Weight​	~0.7 kg (1.5 lbs) (including baseplate)
Certifications​	CE, UL, CSA, RoHS (compliant with EU directives)

ABB CI853K01

Customer Value & Operational Benefits

Field Engineer’s Notes (From the Trenches)

When installing the CI853K01, always use shielded RS232-C cables—unshielded cables can pick up EMI from nearby motors or power lines, leading to data corruption. I once saw a site where a technician used unshielded cables, resulting in a 15% error rate in sensor data. Switching to shielded cables eliminated the problem immediately.

Another gotcha: verify the protocol settings—the module’s default protocol is COMLI, but if you’re using Modbus RTU, you need to configure it via the AC 800M’s programming software (e.g., ABB Control Builder). I’ve fixed countless “no communication” errors by forgetting to switch the protocol from COMLI to Modbus.

If the module’s “FAULT” LED illuminates, check the power supply—the module requires a stable 24V DC supply from the AC 800M backplane. I’ve seen cases where a faulty backplane power supply (outputting 18V DC) caused the module to enter a fault state. Use a multimeter to test the backplane voltage before replacing the module.

Real-World Applications

• Chemical Manufacturing:
  A chemical plant uses the CI853K01 to connect its ABB AC 800M controller to a Siemens S7-1200 PLC (which controls a reactor). The module transmits real-time data (e.g., reactor temperature, pressure) to the PLC, allowing for precise control of the chemical process.
• Power Generation:
  A power plant uses the CI853K01 to link its AC 800M controller to a legacy SCADA system (via Modbus RTU). The module enables bidirectional communication, allowing the AC 800M to send “turbine speed” commands to the SCADA system and receive “generator load” feedback.
• Building Automation:
  A commercial building uses the CI853K01 to connect its AC 800M controller to a Honeywell HMI (which controls the HVAC system). The module transmits data (e.g., room temperature, humidity) to the HMI, allowing facility managers to adjust the HVAC settings remotely.

  

  ABB CI853K01

High-Frequency Troubleshooting FAQ

• Power Supply Failure: The 24V DC supply from the AC 800M backplane is missing or unstable (check with a multimeter);
• Communication Timeout: The module hasn’t received data from the AC 800M controller for more than 1.6 seconds (check the CEX bus cable);
• Protocol Mismatch: The module’s protocol setting (e.g., COMLI) doesn’t match the external device’s protocol (e.g., Modbus RTU).

1. Open ABB Control Builder: Launch the software and connect to the AC 800M controller;
2. Select the CI853K01 Module: Navigate to the “Communication” tab and select the CI853K01;
3. Set Protocol to Modbus RTU: Choose “Modbus RTU” from the protocol dropdown menu;
4. Enter Device Parameters: Input the external device’s IP address, MAC address, and device name;
5. Save Configuration: Click “Save” to apply the changes to the module’s memory.

1. Baud Rate: Ensure the module’s baud rate (e.g., 19,200 bps) matches the external device’s baud rate;
2. Cable Length: RS232-C cables longer than 15 meters can cause signal degradation (use a fiber converter for longer distances);
3. EMI: Ensure the module is installed in a cabinet with adequate shielding (e.g., metal cabinet) to reduce EMI.

Commercial Availability & Pricing